System and method of assembling a protective sports helmet

ABSTRACT

A partial bespoke protective sports equipment to be worn by a player engaged in a sporting activity is provided. The partial bespoke sports equipment system includes methods for acquiring, storing and processing a player&#39;s unique data, namely the anatomical features of the body part against which the partial bespoke equipment is worn. The systems also includes methods of using the player&#39;s unique data to manufacture the partial bespoke protective equipment with a partially custom formed internal padding. The system and method allows for the design and manufacture of partial bespoke protective sports equipment that is purposely designed and manufactured to substantially match the anatomical specifications of the player&#39;s body part.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Utility application Ser. No.17/567,760, filed Jan. 3, 2022, which is a continuation of U.S. Utilityapplication Ser. No. 17/026,882 filed on Sep. 21, 2020, which is acontinuation of U.S. Utility application Ser. No. 15/655,535 filed onJul. 20, 2017, which claims the benefit of U.S. Provisional ApplicationNo. 62/364,629 filed on Jul. 20, 2016, the entire content of which arehereby incorporated by reference in their entirety for all purposes.

TECHNICAL FIELD

This disclosure relates to (i) systems and methods for acquiring,storing and processing a player's unique data, namely the player'sanatomical features, where that player is to wear an article ofprotective sports equipment, (ii) for systems and methods of using theplayer's unique data to manufacture an article of protective sportsequipment with a custom formed internal padding assembly thatsubstantially corresponds to the player's unique data, and (iii) anarticle of protective sports equipment designed using the acquired andprocessed unique player's data and including the custom formed internalpadding assembly that provides improved fit and comfort for the player.Accordingly, the disclosure provides for a system and method to designand manufacture bespoke protective sports equipment that is purposelydesigned and manufactured to match the player's anatomicalspecifications, namely the topography and contours of the player's bodypart.

BACKGROUND

Most, if not all, contact team sports require players to wear protectiveequipment, such as a helmet, while playing the sport during bothpractice and game play. For example, youth, high school, club, collegeand professional levels of football, lacrosse, hockey, baseball andsoftball require players to wear a protective helmet and protectiveequipment for a body part (e.g., shoulder pads for football, hockey andlacrosse, catcher's leg guards and chest guards for baseball andsoftball). This protective equipment generally comprises at least twolayers: a substantially rigid outer shell, typically formed frompolymers and composite materials including plastics, and an internalpadding assembly, which can be formed from a variety of impact absorbingmaterials. Most protective helmets for contact team sports also includea chin strap that secures the helmet on the player's head during thecourse of play such that helmet is not dislodged when the player and/orhelmet receives a first impact whereby the helmet is properly positionedto protect the player from a second impact. Football and lacrossehelmets also include a face guard or face mask that overlie the player'sfacial region. Hockey helmets typically include a face guard, or clearshield that overlies at least the player's eye region. Baseball batter'shelmets typically are “open-faced” and thus lack a face guard, althoughbaseball catcher's helmets include a face guard to protect the catcher.Unlike baseball batter's helmets, softball batter's helmets include aface guard, which typically extends over the player's mouth and jawregion while leaving the eye region open.

Conventional protective equipment, including helmets can be found inmultiple standard sizes depending upon the playing level—youth, varsityor professional—to which the helmet is intended for use. For example,youth level football helmets can be found in a number of standard sizes,including extra-small, small, medium, large and extra-large, where thehelmet size is based upon the circumference of the player's head.Similarly, varsity and professional level football helmets can be foundin a number of standard sizes, including small, medium, large andextra-large, where again the helmet size is based upon the circumferenceof the player's head. For example, a “medium” varsity level footballhelmet is sized for a player having a head circumference of 20.375-22.0inches, a “large” varsity level football helmet is sized for a playerhaving a head circumference of 22-23.5 inches, and an “extra large”varsity helmet is sized for a player having a head circumference of 23.5inches and above. The football helmet's external shell and internalpadding assembly are configured to receive a player's head, so aparticular helmet size is selected for a player based upon his/her headsize, namely his/her head circumference. When properly sized, thefootball helmet should provide a secure fit on the player's head and becomfortable, while not irritating the player when worn during the courseof play.

It is not uncommon for the internal padding assembly found inconventional protective sports helmets to be comprised of multiple padelements that can be selectively adjusted to a limited extent in orderto accommodate a player's (i) head size and (ii) head contours ortopography. However, the extent of that adjustment is limited in anumber of ways, including that the internal pad assembly comprises anarrangement of pad elements each including an elastically deformable,energy absorbing pad member positioned within a pad housing. Thus, theinternal pad assembly is configured in a standard size with maximumdimensions and the internal pad assembly must fit within a standardizedhelmet shell size. It is understood that the helmet shell is formed tobe substantially rigid to withstand multiple impacts and the helmetshell's overall configuration cannot be greatly expanded or contracted.An example of a conventional internal padding assembly is one thatfeatures multiple pad elements each with an inflatable component thatallows for a fluid, such as air, to be used to selectively inflate ordeflate the pad elements to better conform the internal padding assemblyto the player's head size and contours. Examples of a conventionalinternal padding assembly can be found in U.S. Pat. Nos. 6,934,971,8,544,117, and U.S. patent application publication US2015000808.

Conformity of the internal padding assembly to the player's head sizeand contours is limited by a number of factors inherent to pad elements,including, but not limited to, the size and configuration of the padmember, the size and configuration of the pad housings, and theplacement of the pad elements in the padding assembly relative to theplayer's head. As the extent of the adjustment of a conventionalinternal padding assembly to the player's head contours and topographyis limited, the player may perceive the fit of the helmet to beinadequate and/or may not find the fit of the helmet to be sufficientlycomfortable. Thus, the player wearing a conventional protective sportshelmet might not be entirely happy with the helmet, which may impacthis/her selection of the helmet and his/her performance while playingthe contact sport. Even if the player is happy with the comfort of theconventional helmet and accepts the conventional helmet's fit on his/herhead, the helmet may not be ideally positioned and can be susceptible toexcessive movement when the helmet is impacted during the course ofplay.

The apparatus, systems and methods disclosed herein address the problemsdiscussed above and other problems while providing advantages andaspects not provided by conventional protective sports helmets. A fulldiscussion of the features and advantages of the present disclosure isdeferred to the following detailed description, which proceeds withreference to the accompanying drawings.

SUMMARY

The present disclosure provides systems and methods for acquiring,storing and processing a player's unique data set concerning theanatomical features of the player's body part (e.g., head) in order todesign and manufacture a piece of bespoke protective sports equipment(e.g., helmet). The bespoke protective sports equipment can include acustom formed internal padding assembly that can be configured to matchor substantially correspond to the player's unique anatomical body partdata. The bespoke equipment, including its internal padding assembly,provides significantly improved fit and comfort for the player.Accordingly, the disclosure provides for a system and method to designand manufacture bespoke protective sports equipment that is purposelydesigned to either match or substantially correspond to the player'sanatomical specifications, namely the topography and contours of theplayer's equipment body part and facial region, including the jawregion.

The present disclosure also provides a method for manufacturing a pieceof bespoke protective sports equipment. In the context of a bespokehelmet, the method may include placing a scanning hood on a player'shead, selecting a scanning helmet size and placing a scanning helmet ofthe selected scanning helmet size on the player's head over the scanninghood, adjusting the scanning helmet according to the player's wearingpreferences, capturing a helmet scan of the player wearing the scanninghood and scanning helmet with a scanning apparatus, removing thescanning helmet from the player's head and capturing a hood scan withthe scanning apparatus while the player is wearing the scanning hood,opening the helmet scan in three-dimensional software and properlyaligning the helmet scan with a shell template within thethree-dimensional software, opening the hood scan in thethree-dimensional software and properly aligning the hood scan with theproperly-aligned helmet scan within the three-dimensional software,comparing the properly-aligned hood scan with data of the scanninghelmet size and determining whether scanning helmet size tolerances aresatisfied for the properly-aligned hood scan, creating at least oneinsert file from the properly-aligned hood scan, fabricating an insertfrom the insert file, placing the insert into a lower mold section,attaching a backing material to an upper mold section, heating anethylene-vinyl acetate (EVA) cover and attaching the heated EVA cover tothe lower mold section, vacuum-forming the EVA cover to an insertsurface, pouring padding material into the vacuum-formed EVA cover,allowing the poured padding material to cool and solidify into acustomized pad, removing the customized 4 pad from the vacuum-formed EVAcover and installing the customized pad into the customized protectivesports helmet.

The disclosure also provides for a bespoke protective sports equipmentfabricated from a process that comprises the numerous steps discussed inthe foregoing paragraph. Other features and advantages of the disclosurewill be apparent from the following specification taken in conjunctionwith the following drawings. Implementations of the described techniquesmay include hardware, a method or process, or software for a mobiledevice on a computer-accessible medium. The details of one or moreimplementations are set forth in the accompanying drawings and thedescription below. Other features will be apparent from the descriptionand drawings, and from the claims.

Additional advantages and novel features will be set forth in part inthe description which follows, and in part will become apparent to thoseskilled in the art upon examination of the following and theaccompanying drawings or may be learned by production or operation ofthe examples. The advantages of the present teachings may be realizedand attained by practice or use of various aspects of the methodologies,instrumentalities and combinations set forth in the detailed examplesdiscussed below.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawing figures depict one or more implementations in accord withthe present teachings, by way of example only, not by way of limitation.In the figures, like reference numerals refer to the same or similarelements.

FIG. 1A is a perspective view of a bespoke helmet according to exemplaryembodiments of the present disclosure.

FIG. 1B is a rear view of the bespoke helmet of FIG. 1 .

FIG. 1C is an upper perspective view of a customized internal paddingassembly according to exemplary embodiments of the present disclosure.

FIG. 1D is a rear perspective view of the customized internal paddingassembly of FIG. 1C.

FIG. 1E is a lower perspective view of the customized internal paddingassembly of FIG. 1C.

FIG. 1F is a front view of a customized internal padding assemblyaccording to exemplary embodiments of the present disclosure.

FIG. 1G is an upper perspective view of a customized internal paddingassembly according to exemplary embodiments of the present disclosure.

FIG. 1H is a rear perspective view of the customized internal paddingassembly of FIG. 1G.

FIG. 1I is a lower perspective view of the customized internal paddingassembly of FIG. 1G.

FIG. 2A illustrates a side view of a player wearing a scanning hoodaccording to exemplary embodiments of the preset disclosure.

FIG. 2B illustrates a surface of a scanning hood according to exemplaryembodiments of the present disclosure.

FIG. 3A illustrates a scanning helmet and a scanning apparatus accordingto exemplary embodiments of the present disclosure.

FIG. 3B illustrates the scanning helmet and scanning apparatus of FIG.3A.

FIG. 4A illustrates a customized padding assembly disposed on aschematic representation of a player according to exemplary embodimentsof the present disclosure.

FIG. 4B illustrates a bespoke helmet with a customized padding assembly,both disposed on a schematic representation of a player according toexemplary embodiments of the present disclosure.

FIG. 5A illustrates an external view of a mold assembly according toexemplary embodiments of the present disclosure.

FIG. 5B illustrates a cross-sectional view of the mold assembly of FIG.5A, taken along line B-B of FIG. 5A, and further showing customizedcasting elements.

FIG. 5C illustrates an exploded perspective view of the mold assemblyand associated customized casting elements of FIG. 5B.

FIG. 6A is an upper perspective view of a custom-selected paddingassembly according to exemplary embodiments of the present disclosure.

FIG. 6B is a rear perspective view of the custom-selected paddingassembly of FIG. 6A.

FIG. 6C is a lower perspective view of the custom-selected paddingassembly of FIG. 6A.

FIG. 6D is a perspective view of a partially-bespoke helmet according toexemplary embodiments of the present disclosure, which includes thecustom-selected padding assembly of FIG. 6A.

FIG. 7 illustrates a method of gathering customized data regardingtopographical features of a player according to exemplary embodiments ofthe present disclosure.

FIG. 8 illustrates a method of analyzing and modifying acquiredcustomized data according to exemplary embodiments of the presetdisclosure.

FIG. 9 illustrates a method of creating inserts from insertmanufacturing files using additive manufacturing according to exemplaryembodiments of the preset disclosure.

FIG. 10 illustrates a method of creating inserts from insertmanufacturing files using subtractive manufacturing according toexemplary embodiments of the preset disclosure.

FIG. 11 illustrates a method of casting customized pads using insertsaccording to exemplary embodiments of the preset disclosure.

FIG. 12 illustrates a method of casting customized pads using inserts,distinct from that shown in FIG. 11 , according to exemplary embodimentsof the preset disclosure.

DETAILED DESCRIPTION

In the following detailed description, numerous specific details are setforth by way of examples in order to provide a thorough understanding ofthe relevant teachings. However, it should be apparent to those skilledin the art that the present teachings may be practiced without suchdetails. In other instances, well known methods, procedures, components,and/or circuitry have been described at a relatively high-level, withoutdetail, in order to avoid unnecessarily obscuring aspects of the presentdisclosure.

While this disclosure includes a number of embodiments in many differentforms, there is shown in the drawings and will herein be described indetail particular embodiments with the understanding that the presentdisclosure is to be considered as an exemplification of the principlesof the disclosed methods and systems, and is not intended to limit thebroad aspects of the disclosed concepts to the embodiments illustrated.

This disclosure relates to (i) systems and methods for acquiring,storing and processing a player's unique data, namely the player'sanatomical features, where that player is to wear protective sportsequipment worn against a body part while engaged in a sporting activity,(ii) for systems and methods of using the player's unique data tomanufacture a piece or article of protective sports equipment with acustom formed internal padding assembly that at least substantiallycorresponds to the player's unique data, (iii) for systems and methodsof using the player's unique data to manufacture the bespoke protectivesports equipment with both a custom formed shell and internal paddingassembly that match the player's unique data. As one example of theprotective sports equipment, a protective sports helmet is designedusing the acquired and processed unique player's data and including thecustom formed internal padding assembly that provides an improved fitfor the player. As used herein, the term “player” is a person who wearsthe protective sports equipment (e.g., helmet or shoulder pads), isgender neutral and is synonymous with the terms “helmet wearer” or“wearer.” The term “anatomical features” means the dimensions,topography and contours of the player's body part (e.g., head includingthe player's skull, facial region, eye region and jaw region). Becausethe disclosed protective equipment is worn on the player's body part(e.g., head, shoulder, knee, elbow, hip, shins) the “anatomicalfeatures” term includes the outer configuration of the player's bodypart. In the context of a bespoke helmet, the internal padding assemblymakes contact with the player's hair, the “anatomical features” termalso includes the type, amount and volume of the player's hair or lackthereof. For example, some players have long hair, while other playershave no hair (i.e., are bald).

The inventive bespoke protective sports equipment and system can beconfigured as a shoulder pad assembly, an elbow pad, a thigh pad, a kneepad, a shin guard, a chest guard, or a hip pad. Shoulder pad assembliestypically include two arches that overlie the shoulder region, an extentof the back region and an extent of the chest region of the player, aswell as an internal padding assembly affixed to the arches. In thecontext of a protective sports helmet worn by a player engaged infootball, hockey or lacrosse, the disclosed helmet is “bespoke,” meaningthat the internal padding assembly is customized to the player wearingthe helmet because it is purposely designed, configured and manufacturedto match anatomical features of the player's head. Much like a tailorprovides a bespoke suit that is made to order with pants and a jacketthat match the customer's specific anatomical needs (e.g., waist size,chest size, sleeve length), the system and methods disclosed allow for abespoke protective sports helmet that provides improved fit and comfortfor the player wearing the helmet. In another embodiment, the helmet is“fully bespoke,” meaning that both the helmet shell and the paddingassembly are purposely designed, configured and manufactured to matchthe anatomical features of the player's head. In yet another embodiment,the disclosed helmet and its internal padding assembly are “partiallybespoke,” meaning that the helmet and the padding assembly are purposelydesigned and configured to substantially correspond to the anatomicalfeatures of the player's head. In this embodiment and as explainedbelow, the internal padding assembly of the partially bespoke helmet iscomprised of an arrangement of pads that are selected from a largenumber of pre-manufactured pads. In all three versions—bespoke, fullybespoke and partially bespoke—highly sensitive scans of the player, withand without a helmet, are conducted to capture his/her anatomicalfeatures to help design the internal padding assembly.

The disclosed system and methods may be used to design and manufacturean article of bespoke protective equipment worn against the player'sbody part while engaged in playing the sport. The following paragraphsfocus on the system and methods used to design and manufacture a bespokeprotective sports helmet for a football player, hockey player, orlacrosse player or any other player in a contact sport wherein thehelmet is designed and intended to receive, withstand and absorbmultiple impacts during the course of play. As discussed below, thedisclosed bespoke protective sports helmet for football, hockey andlacrosse players include at least two layers: (i) an outer shelltypically formed from polymers and composite materials, includingplastics and carbon fiber-reinforced polymers, and (ii) an internalenergy attenuating assembly which is formed from cast urethane foam andis configured to match the player's head topography. The outer shell canbe formed from materials that provide it with a generally rigidconfiguration in a pre-impact state, however, the outer shell mayexperience some elastic localized deformation in response to an impactor series of impacts in an impact state. Because this localizeddeformation is elastic, the outer shell returns to its originalconfiguration of the pre-impact state. The disclosed system and methodsmay also be used to design and manufacture a bespoke protective helmetfor baseball, namely a batter's helmet or a catcher's helmet, wherethese helmets can receive a number of high velocity impacts from athrown or batted baseball.

Bespoke Helmet and System

In the bespoke helmet and system embodiment, the disclosed system andmethods include a number of processes and sub-processes that are used toacquire and process data concerning the player's unique anatomicalfeatures and then use the processed data to manufacture a bespokeprotective sports helmet, or a customized helmet, 2, exemplary shown inFIG. 1A, with a customized internal padding assembly 4, exemplary shownin FIG. 1C that matches the player's unique data. The bespoke helmet 2includes a face guard or facemask 13 and a chin strap assembly 17 thatsecures the helmet 2 to a desired wearing position on the player wearingthe helmet 2. Those processes and sub-processes, as well as the bespokeprotective sports helmet, are discussed below.

A method for acquiring, storing and processing a player's unique data,namely the player's anatomical features, commences with conducting atleast two scans of the player's head H and facial region F where onescan involves the player P wearing a scanning hood 10 and a scanninghelmet 15, and a second scan involves the player P wearing only thescanning hood 10. A person skilled in the art recognizes that the orderof the first and second scans can be reversed. FIGS. 2A-3B and 7illustrate a process for acquiring the player's unique anatomicalfeature data while he or she is wearing the scanning hood 10 alone, andwearing both the scanning hood 10 and the scanning helmet 15. As aninitial step, the scanning hood 10 is placed on, or over, the head H ofthe player P. The scanning hood 10 may be a flexible apparatus sized tofit over the player's head H and achieve a tight or snug fit around theplayer's head H due to elastic properties and dimensions of the scanninghood 10, as can be seen in FIG. 2A. The scanning hood 10 provides forincreased accuracy when performing a scan of the player's head H byconforming to the anatomical features the player's head H and facialregion F, namely the topography and contours of the head H and facialregion F, while reducing effects of hair. The scanning hood 10 may bemade from neoprene, lycra or any other suitably elastic material knownto those skilled in the art. Once the scanning hood 10 is placed overthe player's head H, the player and/or another person such as anoperator may verify that the scanning hood 10 is appropriatelypositioned and oriented on the player's head H. The scanning hood 10 isre-adjusted if the scanning hood 10 is found to not be appropriatelypositioned on the player's head H or is uncomfortable. In someembodiments, it is ensured that the scanning hood 10 fully covers theportions of the player's head H (e.g., upper jaw regions) that contact acustomized internal padding assembly 4. In some embodiments, thescanning hood 10 is positioned to fully cover the player's brow line,including the eyebrows. In the event the body part to be scanned is notthe player's head, the hood 10 can be configured as a body part scanninginterface article, such as a wrap or sleeve, that envelops the body partto be scanned and subsequently protected by the bespoke protective bodypart equipment.

A size for the scanning helmet 15 is then selected from a range ofscanning helmet 15 shell sizes. As an example for an adult player P, thescanning helmet 15 shell sizes may include medium, large andextra-large, although additional or intermediate sizes are certainlywithin the scope of this disclosure. The selection of the scanninghelmet 15 shell size may be by determined by previous player experiencesor by estimations or measurements taken during or before the acquisitionof the player's unique data. Once the size of the scanning helmet 15 isselected, the scanning helmet 15 is placed over the player's head Hwhile the player P is wearing the scanning hood 10. After the scanninghelmet 15 is placed on the player's head H, the player adjusts thescanning helmet 15 to a preferred wearing position or configuration,which includes adjusting the chin strap assembly 17 by tightening orloosening it. It is not uncommon for a player P to repeatedly adjust thescanning helmet 15 to attain his or her preferred wearing positionbecause this position is a matter of personal preference. For example,some players prefer to wear their helmet lower on their head H withrespect to their brow line, while other players prefer to wear theirhelmet higher on their head H with respect to their brow line. Thepreferred wearing position is also a function of the face guard 13 andthe player looking through the face guard 13 to assess the field ofview.

As can be seen in FIGS. 3A and 3B, the scanning helmet 15 includes thechin strap 17, one or more apertures 20 formed in the helmet shell andan internal scanning padding assembly 16. The position, number and shapeof the apertures 20 in the scanning helmet 15 are not limited by thisdisclosure. These apertures 20 allow certain portions of the scanninghood 10 to be seen when the scanning helmet 15 is worn over the scanninghood 10 on the player's head H. In some embodiments, one or morereference markers 21 (shown exemplarily in FIG. 2A) are placed onparticular points on the scanning hood 10 through the apertures 20, oron other parts of the scanning hood 10 not covered by the scanninghelmet 15, while the scanning hood 10 and scanning helmet 15 are beingworn by the player. The particular points may correspond with markingson the scanning hood 10, or with the apertures 20 or other features onthe scanning hood 10 or scanning helmet 15. The reference markers 21 areused to aid in the orientation and positioning of the scanning helmet 15and/or the scanning hood 10 relative to each other, relative to featureson the scanning hood or helmet, or relative to the player's head H, aswill be described below. The reference markers 21 may attach to thescanning hood 10 using adhesives or using any other mechanical orchemical attachment means, and further may be colored or includeelectronic properties or features that affect their visibility duringscanning, and the reference markers 21 may appear in a hood scan and ahelmet scan taken of the player P.

As mentioned above, the scanning helmet 15 includes the face guard 13that is removably attached to a forward portion of the scanning helmet15. The face guard 13 may be used by the player, when wearing thescanning helmet 15, to assist the player in determining a preferredhelmet wearing position. Once the player positions the scanning helmet15 such that a preferred helmet wearing position is achieved, the faceguard 13 is removed, as exemplarily shown in FIG. 3B, to increase theaccuracy of the helmet scan by allowing a scanning apparatus 22 tocapture a greater, and less obscured, portion of the player's face.Although the face guard 13 is removed, the chin strap assembly 17remains secured around the player's chin and jaw thereby securing thescanning helmet 15 in the preferred helmet wearing position during thesubsequent scans.

After the player P determines and indicates to an operator that thescanning helmet 15 is properly positioned on the player's head H, theoperator conducts a first helmet scan of the player P and the scanninghelmet 15 while the player P is wearing both the scanning hood 10 andthe scanning helmet 15. The player P and helmet scan is taken by ascanning apparatus 22 utilizing one or more image sensors (e.g.,cameras), lasers (e.g., LiDAR) or other scanning technologies (e.g.,contact scanning, laser triangulation scanning or structured lightscanning). In some embodiments, the scanning apparatus 22 is a single,hand-held unit, such as a personal computer, tablet or cell phone thatan operator holds and moves around the player's head H and the scanninghelmet 15 to capture images of both. In some embodiments, a plurality ofscanning apparatuses 22 is arranged in a pre-determined pattern andorientation relative to the scanning subject, or player P. In someembodiments, photographs are taken of the player P wearing the scanninghelmet 15 and used for reference to properly align a hood scan, asdescribed below. Further, physical measurements of the player P wearingthe scanning helmet 15 can be taken and used to properly align the hoodscan. Regardless of whether a single scanning apparatus 22 or multipleapparatuses 22 are employed, a plurality of scanning images, or asubstantially continuous moving set of images, can be captured andrecorded. These images can then be “stitched” or electronically combinedtogether in various ways to produce a single three-dimensional scan, ordata file.

In some embodiments, the reference markers 21 on certain portions of thescanning hood 10 can be raised or recessed structures (e.g., dimples).The number of markers 21 on the scanning hood 10 is such that there areenough markers 21 to allow for the accurate creation of thethree-dimensional model, but low enough to make processing of the modelefficient. For example, four and twelve markers 21 per square inch maybe used. A person skilled in the art recognizes that more or fewermarkers 21 may be used to alter the processing times and the accuracy ofthe model.

The markers 21 on the scanning hood 10 contain unique portions 27 toenable the computerized modeling system to efficiently and accuratelyprocess the images or video. An example of such unique portions 27 isexemplarily shown in FIG. 2B. One method of creating these uniqueportions 27 is to divide each dimple into four sections and fill eachsection with a different color. It is to be understood that more orfewer than four sections can also be employed, and that differentpatterns in each section can also be employed. In addition, to ensurethat the computerized modeling system can distinguish each uniqueportions 27 from one another, the color sections of the unique portions27 may be rotated relative to each other. For example, a top section ofa unique marker may be colored red, while the adjacent unique marker mayhave the bottom section colored red. A person skilled in the artrecognizes that uniquely marking each unique marker can be accomplishedin other ways or combinations of other ways, including using differentshapes, textures, numbers, letters, etc.

A scanning apparatus 22, such as a camera, is then utilized to obtaineither two-dimensional images or video of the scanning hood 10 from anumber of different angles or points of view. The images or video arethen provided to a computerized modeling system, which first roughlydetects the edges of scanning hood 10 in each image or frame of thevideo. For example, Sobel edge detection or Canny edge detection may beused. The computerized modeling system may then remove parts of theimages or frames of the video that are known to not be contained withinthe scanning hood 10. This reduces the amount of data that will need tobe processed by the computerized modeling system in the following steps.In addition, the removal of the parts of the images or frames of thevideo that are known to not be contained within the scanning hood 10reduces the chance of errors in the following steps, such as thecorrelating or matches of a reference marker 21 with the background ofthe image.

Next, the computerized modeling system processes each image or frame ofvideo to detect the reference markers 21, which in some embodiments arethe unique markers 27 on the scanning hood 10. After detecting thereference markers 21, the computerized modeling system correlates ormatches as many reference markers 21 in each image to other referencemarkers 21 in other images or frames of the video. This reference marker21 matching informs the computerized modeling system of the alignment orposition of each image or frame of video. Once the alignment or positionof each image or frame of video is known, mathematical algorithms areutilized to reconstruct a three-dimensional model of the player with thescanning hood 10. Typically, this three-dimensional model of thescanning hood 10 is represented in wire-frame form: a wire-frame modelis a mathematical model in which points that are adjacent on amathematical surface are connected by line segments. Illustrations of awire-frame model for a player wearing a scanning hood 10 are shown inFIGS. 4A and 4B.

Once the three-dimensional model of the player with the scanning hood 10is created, the computerized modeling system determines the scalingfactor of the model. This is possible because the size of the referencemarkers 21 is known and fixed. Thus, the computerized modeling systemdetermines the scaling factor of the model by comparing the known sizeof the reference markers 21 to the size of the reference markers in themodel. Once this scaling factor is determined, the model can be used toaccurately represent the player P.

After the helmet scan, or player and helmet scan, is taken, an operatorconfirms that the helmet scan is of adequate quality based uponpredetermined quality criteria, and/or a visual or manual inspection ofthe helmet scan. These scan quality criteria include scan continuity,the inclusion of wrinkles or other perturbations, and recognition and/orvisibility of the reference markers 21 or player facial features. If thehelmet scan quality is determined to be of inadequate quality, a newhelmet scan is taken of the player P and the scanning helmet 15. If thissecond helmet scan quality is determined to satisfy the scan qualitycriteria and/or the visual or manual inspection, then this helmet scanis then saved to a local storage or uploaded to a remote storage orcloud storage device hosted by a separate entity and accessible to theoperator. The helmet scan can be saved as a helmet scan data file, andthe helmet scan data file can be saved and/or uploaded to a centralserver.

Following a successful helmet scan, the scanning helmet 15 is removedfrom the player's head H. The scanning helmet 15 is removed such thatthe reference markers 21 on the scanning hood 10 are not disturbed ordisplaced. While the player P is wearing the scanning hood 10, but notthe scanning helmet 15, a hood, or a player and hood, scan is taken withthe scanning apparatus 22. The hood scan can be taken by one or morescanning apparatuses 22 in a manner similar to the process describedabove for taking the helmet scan. Similar to the helmet scan, after thehood scan has been taken, the operator confirms that the hood scansatisfies the scan quality criteria, or is approved by a visual ormanual inspection of the hood scan. The scan quality criteria includethe scan continuity, the inclusion of wrinkles or other perturbations,and a recognition and visibility of the reference markers 21 and playerfacial features. If the hood scan quality is determined to be ofinadequate quality, a new hood scan is taken. If this second hood scanquality is determined to satisfy the scan quality criteria and/or thevisual or manual inspection, then this hood scan is then saved to alocal storage or uploaded to a remote storage or cloud storage devicehosted by a separate entity and accessible to the operator. The helmetscan can be saved as a helmet scan data file, and the helmet scan datafile can be saved and/or uploaded to a central server.

The player P removes the scanning hood 10 from his or her head H afterthe hood scan is saved or uploaded. Following each of the helmet scanand the hood scan, the player P may be shown a resulting two-dimensionalor three-dimensional image from each respective scan.

A method for acquiring, storing and processing a player's unique data,namely the player's anatomical features, continues with processing boththe player and helmet scan or “helmet scan,” and the player and hoodscan or “hood scan.” As exemplarily shown in FIG. 8 , the uploadedhelmet and hood scans, or uploaded helmet scan data file and hood scandata file, are opened in software on a computer or other electronicdevice. In some embodiments, the software is three-dimensional software,which may be Pro/ENGINEER, PTC Creo, SolidWorks, Fusion 360 orRhinoceros. The uploaded helmet and hood scans, or uploaded helmet scandata file and hood scan data file, can be opened within or alongside, ageneral helmet shell template image, a minimum certified surface (MCS)template image, blank insert files in the three-dimensional softwareand/or a customized player helmet shell template or a “helmet shelltemplate” that includes a plurality of layers including, but not limitedto, one or more shell size reference layers, a Minimum Certified Surface(MCS) layer and an insert blank layer, as will be described below. Thehelmet shell template may be a pre-loaded image, model or set ofcoordinates corresponding to an existing helmet shell, while the MCSlayer may be an image or set of coordinates useful in determiningwhether certain tolerances are satisfied through comparisons with otherelectronic files or data. Similar to the process described above, atthis stage, an operator confirms that the helmet and hood scans satisfyscan quality criteria. Such a confirmation can be performed usingnumerical quality criteria or algorithms, and/or by a visual or manualinspection of the helmet and hood scans or of the uploaded helmet scandata file and hood scan data file.

Following a confirmation of adequate helmet scan quality, the helmetscan is selected and aligned three-dimensionally within thethree-dimensional software. In some embodiments, the helmet scan isaligned in three-dimensional space according to a pre-set template,which may be the helmet shell template. The proper alignment of thehelmet scan may be made with reference to a predetermined set ofcoordinates or reference points, a helmet shape or the player's facialfeatures (e.g., brow region, upper lip region, nose bridge or nose tip)within the helmet shell template, or using another method or referencesystem. In particular, the helmet scan can be aligned with one or moreof the helmet shell size reference layers within the helmet shelltemplate, or one or more features represented in the one or more of thehelmet shell size reference layers within the helmet shell template.Such an alignment can be made along, or according to, multiple axes. Aconfirmation that the helmet scan is properly aligned in thethree-dimensional software and/or the shell template is then made. Sucha confirmation can include a visual and/or manual inspection of thealignment. When the helmet scan is determined to be improperly alignedin the three-dimensional software and/or with the helmet shell template,the helmet scan is realigned until the helmet scan is properly alignedin the three-dimensional software and/or with the helmet shell template.

Following a confirmation of adequate hood scan quality, the hood scan isselected and then aligned three-dimensionally within thethree-dimensional software. The proper alignment of the hood scan may bemade with reference to a predetermined set of coordinates, referencepoints, reference markers 21 and/or facial features within theproperly-aligned helmet scan or using another method or reference. Insome embodiments, the facial features in the hood scan, which mayinclude the player's brow region, brow, nose bridge, nose tip or upperlip region, are aligned with a corresponding player facial feature inthe properly-aligned helmet scan. Such an alignment can be made alongmultiple axes. The properly-aligned helmet scan, or reference markers 21therefrom, may be simultaneously viewed from multiple perspectives whenthe hood scan, or reference markers 21 therefrom, is selected andviewed.

In some embodiments, the reference markers 21 and/or the nose region ofthe player are identified in the hood scan and used to properly alignthe hood scan in the three-dimensional software with respect to theproperly-aligned helmet scan, reference markers 21 and/or the player'snose bridge, nose tip or brow in the helmet scan, or other referencemeans or markers from the properly-aligned helmet scan. A confirmationthat the hood scan is properly aligned with respect to aspects of theproperly-aligned helmet scan, the hood template or anotherpre-determined set of coordinates in the three-dimensional software isthen made. Such a confirmation can include a visual and/or manualinspection of the alignment. When the hood scan is found to beimproperly aligned with respect to the above-mentioned criteria, thehood scan is realigned until it is properly aligned in the softwareprogram.

The properly aligned hood scan may then be compared with known helmetshell size data, or to the properly aligned helmet scan, to check forcertain relative tolerances and relationships. In some embodiments, theproperly aligned hood scan is compared with the Minimum CertifiedSurface (MCS) layer in the helmet shell template corresponding to agiven helmet shell size. The MCS is a reference surface defined by acollection of minimum distance values between an outer surface of theplayer's head H and a helmet shell. An internal padding assemblytypically occupies the MCS when the internal padding assembly isinstalled in a shell of a protective sports helmet. Consistent withindustry standards, every NOCSAE certified protective sports helmet hasan MCS. Ideally, the player's head H should not penetrate or extend intothe MCS when the player P wears the protective sports helmet. An MCSvalue, or set of values, may vary based on a given helmet shell locationor padding location within the helmet shell. Data from the properlyaligned hood scan and/or properly aligned helmet scan can be used todetermine whether such an MCS is satisfied based on known measurementsof a given helmet shell size. Further, the MCS layer of the helmet shelltemplate, or a separate MCS template or data set, can instead, oradditionally, be compared with customized insert files to determinesatisfaction of MCS tolerances, as described below. If the MCS, oranother tolerance measurement, is satisfied through the comparison ofaligned hood scan data and the MCS layer of the helmet shell templatefor the selected shell size, it is determined that a customized helmetmanufactured using the presently disclosed methods can be made for thatplayer P using the given helmet shell size.

If, however, the MCS, or other tolerance measurement, is not satisfiedthrough a comparison of aligned hood scan data and known measurements ofa helmet shell size or the MCS layer of the helmet shell template forthe shell size, it is determined that a bespoke helmet manufacturedusing the presently disclosed methods cannot be made for that player Pusing the given helmet shell size. In this scenario, the player or scanoperator will then select a larger helmet shell size and perform a newhelmet scan and hood scan using a scanning helmet corresponding to thelarger helmet shell size. This selection process can continue until ahelmet and hood scan are produced where data from the properly alignedhood scan satisfies the MCS layer of the helmet shell template, or othertolerance measurement, such that a comparison of aligned hood scan dataand the MCS layer of the helmet shell template for the selected shellsize allows a customized helmet manufactured using the presentlydisclosed methods to be made for that player using the given selectedhelmet shell size.

When the MCS, or other tolerance measurement, is not satisfied through acomparison of aligned hood scan data and the MCS layer of the helmetshell template for the selected shell size, or known measurements of agiven helmet shell size, and it is determined that a customized helmetmanufactured using acquired customized helmet data cannot be made forthat player using the given helmet shell size, the scan operator maycompare the aligned hood scan data to known measurements of a helmetshell larger than the selected helmet shell size. When such a largerhelmet shell size is selected and the aligned hood scan data satisfiesthe MCS layer of the helmet shell template of the larger shell size orknown data of the larger helmet shell size, a customized protectivesports helmet can be manufactured using the larger shell size.

Additionally, at least a portion of the properly-aligned andMCS-verified hood scan may be inset by a pre-determined distance and/ora player-preferred distance, as is further described below, to create acompression fit when the helmet is worn on the head of the player. Thisresults in a customized padding assembly slightly compressing to form aninterference fit with the player's head H when the helmet is worn by theplayer P. Such alterations include changing the size, shape, orientationor number of customized pads used in the manufacturing of the customizedhelmet.

Following the selection of an appropriate helmet shell size for a givenplayer's customized helmet data, insert files, or insert manufacturingfiles, are created in order to form a set of inserts for the formationof customized helmet pads 54 that form the customized internal paddingassembly 4. The insert files are created using the acquired andprocessed unique player and helmet data acquired from the aligned helmetand hood scans, and may further be created using an insert layer of thehelmet shell template. Boolean operations can be used to create theinsert files, as will be described below. The insert files may alsoincorporate various additional factors, variables or considerations inaddition to the player's unique data gathered from the aligned helmetand hood scans. For example, the insert files may be adjusted based onthe helmet shell size selected.

In some embodiments, a degree of inward pressure against a player's headH is desired while the bespoke helmet is worn by the player P. Theinward pressure may be created by the shape, size and/or orientation ofone or more customized pads, an arrangement of multiple customized pads,the helmet shell, a spacing element disposed between the helmet shelland one or more of the customized pads, and/or other features of thebespoke helmet. According to some embodiments, the inward pressure isgenerated by expansive, or restoring, forces of one or more pads thatare slightly compressed when the player P wears the helmet on his or herhead H relative to the pads' relaxed state when the customized helmet isnot worn by a player P. The existence or degree of inward pressure canbe selected from a range of pre-set degrees, or can be specified by themanufacturer of the customized helmet along with input from the playerP. In other words, the insert files can be designed to create insertsthat form a customized padding assembly with non-compressed innerdimensions that are less than a volume occupied by the player's head H,and/or the player P wearing the scanning hood.

In some embodiments, the creation of the insert files accounts for suchinwardly directed pressure applied by the internal padding assembly onthe player's head H. The inward pressure can be created, or adjusted, byaltering the acquired player data and/or helmet data and measurements.For example, an insert file is adjusted to create a dimensional inset ina customized internal pad manufactured using the insert file. Theresulting dimensional inset may increase the customized pad's thicknessat one or more locations or the pad's overall thickness. As a result,the customized helmet has customized internal pads that feature an innersurface that is dimensioned further from the inner surface of the helmetshell and thereby slightly compress to form an interference fit with theplayer's head H when the helmet is worn by the player P. Suchalterations include changing the size, shape, orientation or number ofcustomized pads used in the manufacturing of the bespoke helmet.Further, the insert files can additionally compensate for a thickness ofthe scanning hood by including an additional compensating dimensionalinset, corresponding to the thickness of the scanning hood, to moreaccurately reflect the actual topography of the player's head H, ratherthan the scanning hood on the player's head H. These alteration factorsmay be applied to any of the helmet scan, hood scan, properly-alignedhelmet scan, properly-aligned hood scan and insert files during theprocessing of the images that allow for the manufacture of thecustomized helmet.

In some embodiments, a three-dimensional blank insert is placed near, oron, the properly-aligned hood scan in the three-dimensional software.The three-dimensional blank insert may be included with the insert layerof the helmet shell template. Then, optionally, the properly-alignedhood scan is inset by a particular distance or degree, which may bespecific for the creation of that particular customized pad. A Booleanoperation, or intersection calculation, may then be performed between asurface of the three-dimensional blank insert and at least a portion ofthe aligned, or aligned and inset, hood scan. An insert file is thencreated, a surface of which reflects the player's head topography in thesurface of the insert file.

In some embodiments, the creation of the insert file accounts forvarious player preferences regarding the fit of one or more paddingelements. For example, if a player prefers a looser or tighter fittingcrown pad, such a preference can be accommodated for in the making ofthe customized helmet with customized pads. The preference can beaccommodated by altering the size, shape, orientation or number of thecustomized internal pads used in the manufacturing of the customizedhelmet. This preference factor may be applied to any of the helmet scan,hood scan, properly-aligned helmet scan, properly-aligned hood scan andinsert file. Additionally, the insert files may be refined, smoothed oroptimized manually, by software or by electronic computer-based toolsbased on a range of factors including, but not limited to, electronicerrors, non-continuous surfaces, overlapping surfaces, meshinginconsistencies, meshing anomalies and/or meshing gaps. Such operationsmay be performed without substantially, or in any degree, altering ashape of any of the aforementioned scans or files, and merely may refineor optimize the electronic files in preparation for customized helmetmanufacturing.

The customized internal padding assembly 4, as exemplarily shown inFIGS. 1G-II comprises individual pad members for use in the customizedhelmet. For example, the customized pad members include a customizedfront pad 80, a customized crown pad 81, a customized rear pad 82, acustomized left side pad 83, a customized right side pad 84, acustomized occipital pad 85, a customized left jaw pad 86 and acustomized right jaw pad 87, wherein the jaw pads overlie an extent ofthe jaw or mandible of the player when the bespoke helmet is worn. It isto be understood that the insert files may be used to create more orfewer customized pads for a given customized helmet. One insert file maybe used to create one customized pad, or a single insert file may beused to create multiple customized pads. The insert files, which may bepolygon mesh files and/or files in .mesh format, may be checked for filequality, mesh quality and mesh continuity. The insert files may beexported, or converted, to a STereoLithography (STL) or an OBJ/.OBJ fileformat. The insert files are saved to a local storage device or uploadedto a remote storage device, which may be a remote storage device, acloud storage system or a central server.

The above steps substantially complete the method for acquiring, storingand processing a player's unique data and the processing of both thehelmet scan and the hood scan.

The systems and methods of using the player's unique data to manufacturethe customized helmet with a customized internal padding assembly thatsubstantially corresponds to the player's unique data includes creatinginserts 40 that are used to form the customized internal paddingassembly. Inserts 40, created using the insert files, are bestillustrated in FIGS. 5A-5C. The inserts 40 are unique for each player,and further are unique for each customized pad or group of padsfabricated for use in a customized helmet. A given insert 40 is createdfrom an insert file using an additive or subtractive manufacturingprocess. The additive manufacturing process includes three-dimensionalprinting. In such a process, the insert file is transferred to athree-dimensional printing apparatus, which then three-dimensionallyprints a corresponding insert 40. The additive manufacturing processcreates the insert by, continuously or sequentially, adding material tocreate the insert 40. The material used to create the insert 40 can beany number of polymers, metals, ceramics or other materials.

A subtractive manufacturing process includes machining and any number ofmachining tools known to those skilled in the art. Such machine toolscomprise mills, lathes, saws, drills, bores and reamers, among manyothers, and operate using manual controls and/or Computer NumericControls (CNC). Such CNC machine tools incorporate Computer-AidedManufacturing (CAM) controls and software to enable precise electroniccontrol of the manufacturing process, and CAM cutting paths may becalculated, before subtractive manufacturing, based on the insert file.The subtractive manufacturing process creates the final insert 40 from ablank made of any number of polymers, metals or ceramics by removingmaterial from the blank with one or more machine tools.

Following insert 40 creating using either the additive or subtractiveprocess, the inserts 40 may be checked for adequate quality, continuityand other properties for use in the manufacturing of customizedcomponents for a customized protective sports helmet. Inserts 40determined to be of adequate quality, continuity and/or other propertiesfor use in the manufacture of a customized protective sports helmet padare used in the creation of customized helmet pads.

The disclosure continues with the manufacture of customized protectivehelmet pads. An example of an apparatus for manufacturing bespoke helmetpads, as illustrated in FIGS. 5A-5C, includes a mold 28. The mold 28,which can be called a master mold, includes one or more components usedto cast customized, or bespoke, helmet components or helmet pads. Insome embodiments, the mold 28 includes an upper section 32 and a lowersection 36. The upper section 32 and lower section 36 form an internalcavity 44 when the upper section 32 is placed on top of the lowersection 36. The mold 28 may be made from any suitable material, and ismade of urethane in some embodiments.

Prior to casting, a weight of the urethane casting material is verifiedbased upon volume calculations derived from the Boolean operationsand/or insert files, described above. Further, a ratio of isocyanate andresin may be verified for the customized pad, or customized part, beingcreated. The ratio may be determined for a particular type of pad, suchas a front pad, and/or may be determined for a particular player basedon one or more of player preferences, player head topographicalfeatures, player history, player skill level and player position. It maybe understood that various properties of a finished and cast customizedpad, such as hardness and compression deflection ratings, may be alteredby adjusting the aforementioned ratio of isocyanate and resin.

One or more inserts 40, created as described in the preceding sections,are placed into the internal cavity 44, and the insert 40 may be placedsubstantially within a portion of the internal cavity 44 formed in thelower section of the mold 36. A velcro panel, or a loop panel, may beaffixed to a portion of the upper mold section 32. The loop panel may beaffixed to the upper mold section 32 using adhesives, or any othermechanical attachment system.

A backing material 48, which in some embodiments is nubuck, may then besecured to the upper section of the mold 32 via a positioning apparatus,or a backing loop, adhesives, magnets, vacuum-forces or any othermechanical attachment system. The backing loop can be an embroideryloop, and the backing material 48 may be secured to the positioningapparatus using various mechanical fasteners. When employed, thepositioning apparatus facilitates a consistent placement of the backingmaterial 48 relative to the upper section of the mold 32. The backingmaterial 48 may also be waterproof or water resistant. The positioningapparatus may attach to the upper section of the mold 32 by conventionalfastening means, including mechanical fasteners, mechanical positioningdevices, magnets and/or adhesives. When the positioning apparatus,including the attached backing material 48, is properly attached to theupper section of the mold 32, the backing material 48 is disposed on anunderside of the upper section of the mold 32 when the upper section ofthe mold 32 is properly placed on the lower section of the mold 36. Anelectronic identification device, which may be a Radio FrequencyIdentification (RFID) device, may be attached to the backing material 48and used to verify that the correct insert 40 is being used for themanufacturing of the correct customized pad for the correct player.

When the mold upper section 32 is properly placed on top of the moldlower section 36, a vent stem, configured as a threaded male member, mayallow gasses to escape the internal cavity 44. The vent stem may beselectively opened to allow various flow rates when the threaded vent isopened. In some embodiments, the vent stem is placed into a receptaclein the upper mold section 32. Such a placement ensures the correctlocation of the threaded vent relative to the backing material. The ventstem may also be secured to the backing material 48. When formingcertain customized pads, for example jaw pads, crown pads and rear pads,the vent is left in place when the customized pad is completed, andserves to aid in the attachment of the customized pad to the helmetshell. When forming other customized pads, for example occipital, frontand side pads, all or a portion of the vent is removed from thecustomized pad when the customized pad is completed.

In some embodiments, the vent comprises a channel formed in one or moreof the upper mold section 32 and the backing material 48, and gasses areselectively allowed to pass from the internal cavity 44 to the exteriorof the top mold section via the channel. In a further embodiment, agrommet formed in the upper mold section 32 frictionally secures, andproperly aligns, the vent stem relative to the upper mold section 32,internal cavity 44 and/or the backing material 48.

In some embodiments, a pre-formed insert, or a high-ratio internalinsert, may be attached to the upper and/or lower mold sections 32, 36.The pre-formed internal insert may have a particular ratio of isocyanateto resin, and may have a relatively high ratio of isocyanate to resinrelative to the urethane cast material used to form the customized pad.In some embodiments, a plug in the high-ratio internal insert mates witha grommet in the upper mold section 32 to thereby secure the high-ratiointernal insert in place during the molding process. The urethanecasting material may, wholly or partially, surround the high-ratiointernal insert during the molding process such that the high-ratiointernal insert becomes a portion of the completed customized pad. Insome embodiments, a high-ratio internal insert may be used in thecasting of a customized front pad, occipital pad and jaw pad.

A forming element, which may be formed from silicone, may be placed intothe mold cavity 44 during molding. The forming element may be freelyplaced into the mold cavity 44, or may be affixed to one or more of theupper or lower mold sections 32, 36, high-ratio internal insert orinsert 40, and may serve to create desired shapes, forms, tolerancesand/or characteristics of the final customized pad. In some embodiments,the forming element creates a particular radius, or radii, on thecustomized pad, and the forming element may further be employed whenforming a customized front pad and a customized occipital pad.

At least one badge which may include indicia such as a player's name,jersey number and/or signature, and/or a name, slogan or images of anentity such as a company, may be affixed to one of the completedcustomized pads. In particular, a player identification badge 41, asexemplarily shown in FIG. IF, may be disposed on a customized rear padwhile a product identification badge, identifying the helmet modeland/or manufacturer, may be placed on a customized crown pad. Theidentification badge 41 may also include a reproduction of the player'sactual signature 43. In addition to enhancing aesthetic appeal andproduct desirability, the identification badge 41 is useful in helping aplayer quickly ascertain his or her helmet from among a group ofsimilarly-appearing helmets. A spacing member, which may be a badge, maybe secured to an insert 40 via adhesives or another mechanicalattachment method to conform the shape of the finalized customized padto accommodate the attachment of the identification badge and theproduct identification badge to the corresponding customized pads andensure a proper fit within the customized helmet.

A covering material 52 is heated for use in the casting process. Thecovering material 52 may include Ethylene-Vinyl Acetate (EVA) and/or mayinclude expanded vinyl and Lycra (elastic polyurethane fabric) layers.The covering material 52 may form a complete or partial moisture and/orgas barrier. In some embodiments, the covering material 52 includes EVAin the form of a foam. Further, the EVA in the covering material 52 mayrepresent closed cell foam and may thereby form the moisture barrier.

The covering material 52 may be heated in an oven in isolation, may beheated in the oven while attached to a covering material positioningapparatus, or may be heated in the over while attached to a portion ofthe lower mold section 36. The covering material positioning apparatusfacilitates a consistent placement of the covering material 52 relativeto the lower section of the mold 36. Upon the covering material 52reaching a pre-set temperature, or a pre-set temperature range, thecovering material 52 (optionally via the covering material positioningapparatus and/or a portion of the lower mold section 36) is attached tothe lower section of the mold 36 by conventional fastening methods,including mechanical fasteners, mechanical positioning devices, magnetsand/or adhesives. The pre-set temperature, or temperature range, may bea temperature, or temperature range, appropriate for covering materialvacuum forming, such that the covering material will deform, or respondto, the vacuum-forming by a particular degree to adequately form to theinsert 40 and lower mold section 36. When the covering material 52 isproperly attached to the lower section of the mold 36, the coveringmaterial 52 is disposed over the insert 40, such that the insert 40 isdisposed substantially between the covering material 52 and the lowersection of the mold 36 within the internal cavity 44.

When the covering material 52 is properly attached to the lower sectionof the mold 36 and the covering material 52 is thus properly disposedover the insert 40 as described, a vacuum apparatus is operated andcreates a partial or complete vacuum within the internal cavity 44 andvacuum-forms the covering material 52 to one or more contours of theinsert 40 and/or the lower mold section 36. The vacuum apparatus may bein fluid communication with the internal cavity 44 through a vacuumaperture formed in the lower section 36 of the mold, and the vacuumapparatus may create the partial or complete vacuum within the internalcavity 44 by negatively pressurizing the internal cavity 44 relative tothe exterior of the mold 28 via the vacuum aperture.

In some embodiments, the covering material 52 is vacuum-formed to anupper insert surface 50. In this process, the covering material 52 mayform to, and adopt the shapes and contours of, the upper insert surface50. A weight of the urethane casting material may be checked foraccuracy at this stage.

After the covering material 52 has been vacuum-formed to a surface ofthe insert 40, or the upper insert surface 50, the covering material 52may form a substantially concave surface within the lower section of themold 36. Liquid, solid or semi-solid casting material, which may also becalled urethane and/or padding material, is then poured into thesubstantially concave surface formed in the covering material 52. Thisprocess can be termed ‘casting.’

The casting material includes isocyanate and resin combined at aparticular ratio. As described above, the ratio of isocyanate and resinmay be determined for the customized pad being created. The ratio may bedetermined for a particular type of pad, such as a front pad or a jawpad, and/or may be determined for a particular player based on one ormore of player preferences, player head topographical features, playerhistory, player skill level and player position.

The upper and lower mold sections 32, 36 are then brought substantiallyor wholly together, forming the cavity 44, and the poured castingmaterial is allowed to cool, cure, solidify, and take the form ofportions of the vacuum-formed covering material 52. In particular, alower portion of the casting material, or urethane, may take the form ofthe vacuum-formed covering material 52, which had previously beenvacuum-formed to the upper insert surface 50. Thus, contours and shapesof the upper insert surface 50 and lower mold section 36 are transferredto the vacuum-formed covering material 52 and then to the poured castingmaterial. Further, upper and lateral portions of the casting materialmay take the form of a portion of the upper mold section 32, transferredto the casting material via the backing material 48. After the pouredcasting material cools and solidifies, the now-solidified castingmaterial reflects the shapes and contours of the vacuum-formed coveringmaterial 52 and the upper insert surface 50, as well as the upper andlower sections of the mold 32, 36. Specifically, a lower surface of thesolidified casting material, or an inner surface of the solidifiedcasting material or customized pad, may reflect the shapes and contoursof the vacuum-formed covering material 52 and the upper insert surface50.

After the casting material is cast into the vacuum-formed coveringmaterial 52, pressure may be released from the mold cavity 44. This maybe accomplished by puncturing a seal in the threaded vent, puncturingthe backing material 48, opening a venting element built into the upperor lower mold sections 32, 36 or partially separating the upper andlower mold sections 32, 36.

Following the cooling and/or solidification of the casting material, thecustomized pad is extricated, or de-molded, from the now-separated upperand lower mold sections 32, 36. A sealant material may then be appliedto one or more surfaces of the customized pad. In some embodiments, thesealant material is lycra (elastic polyurethane fiber), or elastane. Insome embodiments, the sealant material is laminated on, or over, one ormore surfaces of the customized pad. In some embodiments, edges of thecustomized pad are sealed with a silicone ring. In some embodiments,edges of the customized pad are molded with silicone, a sprayed orpainted rubberized material or waterproof tape.

If excess, or undesirable, casting material is present on the de-moldedcustomized pad, the excess casting material may be removed by diecutting, or other manual cutting or removal methods. The dies mayinclude two-dimensional dies and/or three-dimensional dies. Onceseparated from the excess casting material, the customized pad may bechecked for various properties, including density, compressiondeflection, size, weight, shape, consistency and color, among otherpossible properties. In some embodiments, in addition to or instead ofindividualized customized pad testing, test samples are cast and testedat various points to ensure the consistency and quality of the castingmaterial. Acceptable ranges or threshold figures may be determined foreach variable for which the customized pad, or test sample, is tested.If a given customized pad or test sample does not meet an acceptablerange or threshold value for one or more properties, the customized isre-cast and again checked for the one or more properties. If the givencustomized pad meets the acceptable range or threshold value for the oneor more properties, the customized pad is suitable for use in acustomized helmet manufactured using acquired customized helmet data.

After one or more customized helmet pads 54 are formed by theabove-described process, the one or more customized helmet pads 54 arethen attached directly or indirectly to the interior surface of a helmetshell for use by the player. An example of a customized internal paddingassembly 4 manufactured using the above-described methods and systems isexemplarily illustrated in FIG. 4A. Further, turning to FIG. 1B, thecustomized helmet 2 may also include a removable external badge 47,adding to the aesthetic appeal and desirability of the customizedhelmet. The external badge 47 may include a range of indicia, images andtext including, but not limited to, a signature of the player.

Fully Bespoke Helmet and System

In the fully bespoke helmet embodiment, the disclosed system and methodsinclude a number of processes and sub-processes that are used to acquireand process data concerning the player's unique anatomical features andthen use the processed data to manufacture a bespoke protective sportshelmet where the helmet shell and the internal padding assembly are bothpurposely designed, configured and manufactured to match the anatomicalfeatures of the player's head. The internal padding assembly ispurposely designed, configured and manufactured in the manner explainedin the foregoing paragraphs of the Bespoke Helmet and System section.The fully bespoke helmet shell is designed based upon (i) the helmet andhood scans discussed in the foregoing paragraphs of the Bespoke Helmetand System section, and (ii) a combination of the player's playing style(including his/her tackling technique), the player's impact history, theplayer's skill level, the player's position(s) (e.g., quarterback, widereceiver, offensive line, linebacker, etc.), and the extent, if any, ofthe player's prior injuries.

With these considerations in mind, the fully bespoke helmet shell candesigned to provide increased protection in a particular region(s) ofthe shell. This increased protection can be accomplished by: increasingthe thickness of the desired shell region, adjusting the materialproperties of the desired shell region (e.g., increasing the stiffnessof the rear region of the shell), or changing the configuration of thedesired shell region including the shell corrugations in that region(e.g., increasing the dimensions of the corrugation in the rear shellregion).

Partially Bespoke Helmet and System

Embodiments of the present disclosure also include processes andsub-processes used to acquire and process data concerning the player'sunique anatomical features and subsequently use the processed data todesign, select and optimize a padding assembly configured tosubstantially correspond to anatomical features of the player's head. Insome embodiments, the internal padding assembly of apartially-customized helmet 1000, or a custom-selected internal paddingassembly 1002, includes an arrangement of custom-selected pads 1004selected from a large number of pre-manufactured pads. FIGS. 6A-6Dillustrate a partially-customized helmet 1000, a custom-selectedinternal padding assembly 1002 and custom-selected pads 1004.

As described in the above-section detailing acquisition of the player'sanatomical features data, process for creating the partially-customizedhelmet 1000 similarly includes gathering dimensional, topographical andpreference data from the player. In particular, similar to the processesdescribed above, the process for creating the partially-customizedhelmet 1000 may include i) placing the scanning hood 10 on, or over, thehead H of the player P, ii) verifying that the scanning hood 10 isappropriately positioned and oriented on the player's head H, iii)selecting a scanning helmet 15 shell size, iv) placing the scanninghelmet 15 over the player's head H while the player P is wearing thescanning hood 10, v) determining a preferred helmet wearing position,vi) obtaining a helmet scan using a scanning apparatus 22, vii) removingthe scanning helmet 15 from the player's head H and viii) obtaining ahood scan using a scanning apparatus 22. However, it is to be understoodthat the process for creating the partially-customized helmet 1000 mayinclude any and all steps, techniques, technologies, methods anddevices, used in any order or combination, from the section detailingacquisition of the player's anatomical features data.

Further, the process for creating the partially-customized helmet 1000may include all steps, techniques, technologies, templates, methods, anddevices as described in the section detailing acquisition of theplayer's anatomical features data. In particular, the process mayinclude ix) confirming adequate helmet scan quality, x) aligning thehelmet scan within three dimensional software according to the helmetshell template, xi) confirming adequate hood scan quality, xii) aligningthe hood scan relative to the aligned helmet scan or other referencepoints, xiii) verification of MCS satisfaction based on knownmeasurements of a given helmet shell size, xiv) creating a dimensionalinset in the aligned and MCS-verified hood scan, xv) accounting forplayer preferences, history, position, skill level or other factors inthe aligned, inset, and MCS-verified hood scan and modifying the hoodscan accordingly and xvi) comparing the aligned, inset, MCS-verifiedhood scan with one or more partially-customized pad selection layers inthe helmet shell template.

The partially-customized pad selection layer may includethree-dimensional models of a range of custom-selected pads 1004. Thecustom-selected pads 1004 are pre-formed, and include a wide range ofphysical characteristics. For example, the custom-selected pads 1004include a variety of lengths, widths, heights, compression deflections,contours, concavities, angles, radii, attachment systems, colors andmaterials, as well as a range of isocyanate to resin ratios. As will beunderstood by one skilled in the art, upon a comparison of the aligned,inset, MCS-verified hood scan data with the one or morepartially-customized pad selection layers in the helmet shell template,a custom-selected internal padding assembly 1002 may be selected forthat player's partially-customized helmet 1000 that includes anarrangement of custom-selected pads 1004. The custom-selected pads 1004may be selected based upon the aligned, inset and MCS-verified hood scandata, a dimensional fit or connection between a particularcustom-selected pad 1004 and a helmet shell, and/or a dimensional fit orconnection between custom-selected pads 1004.

The custom-selected internal padding assembly 1002, as exemplarily shownin FIGS. 6A-6C, comprises individual custom-selected pads 1004 for usein the partially-customized helmet 1000. For example, thecustom-selected pads 1004 include a custom-selected front pad 1080, acustom-selected crown pad 1081, a custom-selected rear pad 1082, acustom-selected left side pad 1083, a custom-selected right side pad1084, a custom-selected occipital pad 1085, a custom-selected left jawpad 1086 and a custom-selected right jaw pad 1087. Further, although theuse of a partially-customized pad selection layer within a helmet shelltemplate is described, it is to be understood that any method of forminga partially-customized helmet 1000 using custom-selected pads 1004selected from a large number of pre-manufactured pads based upongathered player physical data is within the scope of this disclosure.

On-field results of monitored head impact exposures (HIE) collected bythe proprietary technologies owned by the assignee of the presentApplication can be used to inform certain design parameters of thebespoke helmet discussed above. The monitored HIE results were obtainedby the assignee's advanced wearable monitoring systems, that features anarrangement of impact monitoring sensors, disclosed in U.S. patentapplication Ser. No. 13/603,319 and U.S. Pat. Nos. 6,826,509, 7,526,389,8,797,165 and 8,548,768, each of which including the content thereof arehereby incorporated by reference. For instance, a football player'sskill or age level and playing position may, when compared to a largerdatabase of similar players, indicate certain preferred helmet designcharacteristics. These characteristics may provide benefit to playersbased upon expected HIE levels at differing skill/age levels and/oron-field playing positions or groups of playing positions.Hypothetically, a college football quarterback may expect an elevatedHIE metric of high-intensity impacts directed to the back of the head.The bespoke helmet, including the internal padding assembly, can beadjusted to provide greater protection levels accordingly.

Examples of using the HIE results to inform design parameters includeusing the impact data collected and stored in a database to create aposition and/or skill level specific helmet that is designed based upona generic data set based on skill level and position, but not influencedby a specific player's impact results and data. Another example ofutilizing the HIE results includes using the HIE data collected from aspecific player in combination with the broader data that has beencollected and stored in the repository to create a fully personalizedhelmet. Another example of utilizing the HIE results involves installingsensor instrumentation in a player's helmet to enable furthercustomization based on additional data that is collected after a pre-setamount of time or play. This instrumentation is included in thepersonalized helmet to further inform the data set and how to alter theinserts to provide a greater bespoke fit. These examples and the usageof HIE results applies to all three bespoke embodiments discussedabove—the bespoke helmet and system, the fully bespoke helmet andsystem, and the partially bespoke helmet and system.

As is known in the data processing and communications arts, ageneral-purpose computer typically comprises a central processor orother processing device, an internal communication bus, various types ofmemory or storage media (RAM, ROM, EEPROM, cache memory, disk drivesetc.) for code and data storage, and one or more network interface cardsor ports for communication purposes. The software functionalitiesinvolve programming, including executable code as well as associatedstored data. The software code is executable by the general-purposecomputer. In operation, the code is stored within the general-purposecomputer platform. At other times, however, the software may be storedat other locations and/or transported for loading into the appropriategeneral-purpose computer system.

A server, for example, includes a data communication interface forpacket data communication. The server also includes a central processingunit (CPU), in the form of one or more processors, for executing programinstructions. The server platform typically includes an internalcommunication bus, program storage and data storage for various datafiles to be processed and/or communicated by the server, although theserver often receives programming and data via network communications.The hardware elements, operating systems and programming languages ofsuch servers are conventional in nature, and it is presumed that thoseskilled in the art are adequately familiar therewith. The serverfunctions may be implemented in a distributed fashion on a number ofsimilar platforms, to distribute the processing load.

Hence, aspects of the disclosed methods and systems outlined above maybe embodied in programming. Program aspects of the technology may bethought of as “products” or “articles of manufacture” typically in theform of executable code and/or associated data that is carried on orembodied in a type of machine readable medium. “Storage” type mediainclude any or all of the tangible memory of the computers, processorsor the like, or associated modules thereof, such as varioussemiconductor memories, tape drives, disk drives and the like, which mayprovide non-transitory storage at any time for the software programming.All or portions of the software may at times be communicated through theInternet or various other telecommunication networks. Thus, another typeof media that may bear the software elements includes optical,electrical and electromagnetic waves, such as used across physicalinterfaces between local devices, through wired and optical landlinenetworks and over various air-links. The physical elements that carrysuch waves, such as wired or wireless links, optical links or the like,also may be considered as media bearing the software. As used herein,unless restricted to non-transitory, tangible “storage” media, termssuch as computer or machine “readable medium” refer to any medium thatparticipates in providing instructions to a processor for execution.

A machine readable medium may take many forms, including but not limitedto, a tangible storage medium, a carrier wave medium or physicaltransmission medium. Non-volatile storage media include, for example,optical or magnetic disks, such as any of the storage devices in anycomputer(s) or the like, such as may be used to implement the disclosedmethods and systems. Volatile storage media include dynamic memory, suchas main memory of such a computer platform. Tangible transmission mediainclude coaxial cables, copper wire and fiber optics, including thewires that comprise a bus within a computer system. Carrier-wavetransmission media can take the form of electric or electromagneticsignals, or acoustic or light waves such as those generated during radiofrequency (RF) and infrared (IR) data communications. Common forms ofcomputer-readable media therefore include for example: a floppy disk, aflexible disk, hard disk, magnetic tape, any other magnetic medium, aCD-ROM, DVD or DVD-ROM, any other optical medium, punch cards, papertape, any other physical storage medium with patterns of holes, a RAM, aPROM and EPROM, a FLASH-EPROM, any other memory chip or cartridge, acarrier wave transporting data or instructions, cables or linkstransporting such a carrier wave, or any other medium from which acomputer can read programming code and/or data. Many of these forms ofcomputer readable media may be involved in carrying one or moresequences of one or more instructions to a processor for execution.

While the foregoing has described what are considered to be the bestmode and/or other examples, it is understood that various modificationsmay be made therein and that the subject matter disclosed herein may beimplemented in various forms and examples, and that the teachings may beapplied in numerous applications, only some of which have been describedherein. It is intended by the following claims to claim any and allapplications, modifications and variations that fall within the truescope of the present teachings. Other implementations are alsocontemplated

1. A method of assembling a protective sports helmet to be worn by aplayer while participating in a sports activity, comprising: obtaininghead data from a player's head using an electronic device; creating athree-dimensional model of the player's head from the obtained headdata; providing a plurality of digital pad models; providing athree-dimensional helmet model; forming an aligned three-dimensionalmodel of the player's head by positioning the three-dimensional model ofthe player's head within the three-dimensional helmet model; comparingthe aligned three-dimensional model of the player's head against areference surface associated with the three-dimensional helmet model toconfirm that the aligned three-dimensional model of the player's headdoes not penetrate the reference surface; if the alignedthree-dimensional model of the player's head does not penetrate thereference surface, selecting a digital pad model from the plurality ofdigital pad models based upon a comparison of: (i) the alignedthree-dimensional model of the player's head, and (ii) the plurality ofdigital pad models.
 2. The method of claim 1, wherein the step ofobtaining head data from the player's head using the scanning devicefurther includes: selecting a scanning helmet having a size; placing thescanning helmet on the player's head; and capturing a helmet scan of theplayer wearing the scanning helmet with the scanning device.
 3. Themethod of claim 1, wherein the step of forming the alignedthree-dimensional model of the player's head by positioning thethree-dimensional model of the player's head within thethree-dimensional helmet model includes moving the three-dimensionalmodel of the player's head either forward or backward based on theplayer's playing position or playing level.
 4. The method of claim 1,wherein the step of forming the aligned three-dimensional model of theplayer's head by positioning the three-dimensional model of the player'shead within the three-dimensional helmet model includes moving thethree-dimensional model of the player's head either forward or backwardbased on data collected from an on-field wearable monitoring system wornby the player.
 5. The method of claim 1, further comprising the step ofreplacing the aligned three-dimensional model of the player's head witha modified three-dimensional model of the player's head, wherein saidmodified three-dimensional model of the player's head is created byinwardly adjusting the aligned three-dimensional model of the player'shead by a predetermined amount.
 6. The method of claim 5, furthercomprising the step of forming a bespoke pad with a thickness based on:(i) a portion of the modified three-dimensional model of the player'shead, and (ii) the three-dimensional helmet model.
 7. The method ofclaim 6, wherein inwardly adjusting the aligned three-dimensional modelof the player's head by a predetermined amount results in an increase ofthe thickness of the bespoke pad.
 8. The method of claim 6, wherein thestep of forming the bespoke pad includes selecting a compressiondeflection rating of the bespoke pad based on at least one of thefollowing factors: i) the player's impact history, ii) the player'sskill level, or iii) the player's position while participating in thesports activity.
 9. The method of claim 1, wherein an inner surface ofthe obtained pre-manufactured pad does not match an outer surface of theplayer's head.
 10. The method of claim 1, wherein the plurality ofdigital pad models contain: (i) a first digital pad model having a firstthickness, and (ii) a second digital pad model having a secondthickness; and wherein the group of pre-manufactured pads contain: (i) afirst pre-manufactured pad having a first pad thickness equal to the athickness of the first digital pad model, and (ii) a second digital padhaving a second pad thickness equal to the second thickness of thesecond digital pad model.
 11. The method of claim 1, wherein the step ofselecting one digital pad model from the plurality of digital pad modelsbased upon the comparison of: (i) the aligned three-dimensional model ofthe player's head, and (ii) the plurality of digital pad models, furtherincludes determining measurements between the aligned three-dimensionalmodel of the player's head and the plurality of digital pad models. 12.The method of claim 1, wherein the step of selecting one digital padmodel from the plurality of digital pad models based upon the comparisonof: (i) the aligned three-dimensional model of the player's head, and(ii) the plurality of digital pad models, further includes selecting thedigital pad model that will cause the obtained pre-manufactured pad tobe compressed a predetermined amount when the protective sports helmetis worn by the player but prior to an impact being received by theprotective sports helmet.
 13. The method of claim 1, further comprisingthe step of providing a larger three-dimensional helmet model if thealigned three-dimensional model of the player's head penetrates thereference surface.
 14. A method of assembling a protective sports helmetto be worn by a player while participating in a sports activity,comprising: obtaining head data from a player's head using an electronicdevice; providing a helmet shell model and a group of pre-manufacturedpad models within the computer software program; aligning the head datain the helmet model within the computer software program; andidentifying a pre-manufactured pad model from the group ofpre-manufactured pad models, wherein said identified pre-manufacturedpad model is suitable for installation in the helmet model based on acomparison of the helmet model and the aligned head data.
 15. The methodof claim 14, wherein the step of obtaining head data from the player'shead using the scanning device further includes: selecting a fittinghelmet having a size; placing the fitting helmet on the player's head;and capturing data of the player wearing the fitting helmet.
 16. Themethod of claim 14, wherein the step of aligning the head data withinthe helmet model includes modifying the aligned head data by moving thehead data either forward or backward based on the player's playingposition or playing level.
 17. The method of claim 14, furthercomprising the steps of: providing a group of pre-manufactured pads;providing a helmet shell; selecting a pre-manufactured pad from thegroup of pre-manufactured pads based on the identified pre-manufacturedpad model; and installing the selected pre-manufactured pad within thehelmet shell.
 18. The method of claim 14, wherein the step ofidentifying the pre-manufactured pad model from the group ofpre-manufactured pad models, wherein said identified pre-manufacturedpad model is suitable for installation in the helmet model based on thecomparison of the helmet model and the aligned head data furtherincludes selecting a pad model with a thickness based on at least one ofthe following factors: (i) the player's preferences regarding fit of theprotective sports helmet, (ii) the player's impact history, (iii) theplayer's skill level, or (iv) the player's position while participatingin the sports activity.
 19. The method of claim 14, wherein the group ofpre-manufactured pad models contain: (i) a first pre-manufactured padmodel having a first thickness, and (ii) a second pre-manufactured padmodel having a second thickness.